by Gary Jonesby Gary JonesManager, EHS Affairs Manager, EHS Affairs

Graphic Arts Technical Graphic Arts Technical Foundation Printing Foundation Printing

Industries of AmericaIndustries of America412/741-6860412/741-6860

garyjgatf@aol.comgaryjgatf@aol.com

Developing the Developing the Printing Industry’s Printing Industry’s

Ergonomics GuidelinesErgonomics Guidelines

by Danielleby Danielle WaterfieldWaterfield Government Affairs Government Affairs

AssociateAssociate Specialty Graphic Imaging Specialty Graphic Imaging

AssociationAssociation703/359-1304 703/359-1304

dwaterfield@sgia.orgdwaterfield@sgia.org

Printing Printing IndustryIndustry

Background Background Size and ScopeSize and Scope

– One of the Largest Manufacturing Industries One of the Largest Manufacturing Industries – 100,000 Establishments and 1.5 Million Employees100,000 Establishments and 1.5 Million Employees– Over 80%of Printers Have Less Than 20 EmployeesOver 80%of Printers Have Less Than 20 Employees

Types of PrintingTypes of Printing– Divided By ProcessDivided By Process

Lithography, Screen, Flexography, Gravure, DigitalLithography, Screen, Flexography, Gravure, Digital– Divided By ProductDivided By Product

Books, Magazines, Flyers, Textiles, Packaging, Wall Paper, Books, Magazines, Flyers, Textiles, Packaging, Wall Paper, Flooring, Electronics, Dashboards, etc.Flooring, Electronics, Dashboards, etc.

Printing Industry and Printing Industry and ErgonomicsErgonomics

Printing Industry’s ResponsePrinting Industry’s Response Strongly Opposed OSHA’s Regulation Strongly Opposed OSHA’s Regulation

– Not Opposed To Ergonomics Only the Not Opposed To Ergonomics Only the Regulation Regulation

– One Size Fits All, Trigger, Risk Factors, One Size Fits All, Trigger, Risk Factors, Job Protection, Grandfathering and Job Protection, Grandfathering and CostsCosts

Embraced OSHA’s Four Point PlanEmbraced OSHA’s Four Point Plan– First Industry To Sign an Alliance: First Industry To Sign an Alliance:

1 1stst Alliance signed in June, 2002 Alliance signed in June, 2002– Re-signed Alliance In February 2004Re-signed Alliance In February 2004– Agreed To Work With Each Other To Agreed To Work With Each Other To

Identify Solutions To Ergonomic Identify Solutions To Ergonomic Concerns In Printing Concerns In Printing

Printing Industry Printing Industry OSHA Ergo AllianceOSHA Ergo Alliance

ImplementationImplementation

Fund Raising Campaign For Ergo GuidesFund Raising Campaign For Ergo Guides GATF Awarded OSHA Harwood Training GATF Awarded OSHA Harwood Training

GrantGrant– Printing Specific Ergonomics Printing Specific Ergonomics

GuidelinesGuidelines Assembled Ergo Guide Development Assembled Ergo Guide Development

TeamTeam– Printing Industry Safety ProfessionalsPrinting Industry Safety Professionals– Printing Industry Association Safety Printing Industry Association Safety

ProfessionalsProfessionals– Hired Professional Ergonomist Hired Professional Ergonomist

Dr. Phyllis King – U of WisconsinDr. Phyllis King – U of Wisconsin

Printing Industry Printing Industry OSHA Ergo OSHA Ergo

AllianceAllianceImplementation Implementation

Compiled GuidelinesCompiled Guidelines– Collected Information On Collected Information On

Existing Printer ProgramsExisting Printer Programs– Conducted Plant Visits Conducted Plant Visits – Evaluated OptionsEvaluated Options– Produced Suggested SolutionsProduced Suggested Solutions

Developed Support MaterialDeveloped Support Material– VideoVideo– Fact Sheets and Pocket CardsFact Sheets and Pocket Cards– Leaders GuideLeaders Guide

Printing Ergonomics Printing Ergonomics Guidelines Guidelines

Design PrinciplesDesign Principles Helpful But Helpful But NotNot Prescriptive Prescriptive Provide Basic Ergo InformationProvide Basic Ergo Information

– Assessments and SolutionsAssessments and Solutions Provide Specific SolutionsProvide Specific Solutions

– Focus On Jobs With Highest Injury Focus On Jobs With Highest Injury RatesRates

– Present Info On Printing Process Present Info On Printing Process CategoryCategory

Identify Additional ResourcesIdentify Additional Resources Provide Material Appropriate For Provide Material Appropriate For

AudienceAudience Incorporate Visual ImagesIncorporate Visual Images

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramMaterialsMaterials

Leaders GuideLeaders Guide– Guide for Presenting MaterialGuide for Presenting Material

Guide BookGuide Book – Reference Guide for EHS, HR, Reference Guide for EHS, HR,

Supervisors Supervisors Facility ChecklistsFacility Checklists

– General Awareness and Task SpecificGeneral Awareness and Task Specific Fact SheetsFact Sheets

– 10-12 for Supervisors and Employees10-12 for Supervisors and Employees Pocket CardsPocket Cards

– 10-12 for Supervisors and Employees10-12 for Supervisors and Employees Videotape and Videotape and MS PowerPointsMS PowerPoints

– For Employee Training - 1 Hour For Employee Training - 1 Hour

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgram

Leader’s GuideLeader’s Guide Learning ProcessLearning Process Learning StylesLearning Styles Teaching Methods Teaching Methods Planning For TrainingPlanning For Training Ergonomics Program Ergonomics Program

Overview and Overview and MaterialsMaterials

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramEmployer GuidebookEmployer Guidebook

IntroductionIntroduction– Ergonomic Issues & Benefits Ergonomic Issues & Benefits

Program ApproachesProgram Approaches– Mgt & Employee ParticipationMgt & Employee Participation

Worksite EvaluationWorksite Evaluation– Find, evaluate, and identify Find, evaluate, and identify

solutions solutions Controlling Ergonomic Controlling Ergonomic

IssuesIssues– Office ErgonomicsOffice Ergonomics– Common SolutionsCommon Solutions

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgram

Pre-PressPre-Press– Plate MakingPlate Making– Stencil and Screen PreparationStencil and Screen Preparation– Material HandlingMaterial Handling– Cleaning screen meshCleaning screen mesh– Computerized data and design inputComputerized data and design input

PressPress– Loading/unloading paper on pressesLoading/unloading paper on presses– Handling screensHandling screens– Roll tending on web pre-pressRoll tending on web pre-press– Distribution of ink through screens Distribution of ink through screens – Stacking materialsStacking materials– Unloading/bundling signatures on pressesUnloading/bundling signatures on presses

Guidebook Worksite Focus Areas

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramPost PressPost Press

– Guillotine operation and blade Guillotine operation and blade handlinghandling

– Stencil removal from screensStencil removal from screens– Jogging and fanningJogging and fanning– Pocket feedingPocket feeding– Loading finished bundles/products Loading finished bundles/products

into boxesinto boxes

ShippingShipping– Bagging mailBagging mail– Loading/unloading trucksLoading/unloading trucks– Palletizing/shrink Palletizing/shrink

wrapping/strappingwrapping/strapping

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramEmployer Employer GuidebookGuidebookToolboxToolbox

– GlossaryGlossary– Ergonomic Factor Ergonomic Factor

ChecklistsChecklists– Ergonomic FactsheetsErgonomic Factsheets– Pocket CardsPocket Cards– ReferencesReferences– Contacts and HotlinksContacts and Hotlinks

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramFacility ChecklistsFacility Checklists General AwarenessGeneral Awareness

– Preliminary Preliminary EvaluationEvaluation

Task SpecificTask Specific– Office & Computer Office & Computer

WorkstationsWorkstations– General Shop General Shop

WorkstationsWorkstations– Material HandlingMaterial Handling– Hand Tool AnalysisHand Tool Analysis– Production ActivitiesProduction Activities

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramFact SheetsFact Sheets

One-Two Pages LongOne-Two Pages Long Describes Ergonomic Describes Ergonomic

Issues and Solutions Issues and Solutions For A Particular JobFor A Particular Job

Contains Images Contains Images Showing Issues and/or Showing Issues and/or SolutionsSolutions

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramPocket CardsPocket Cards

Designed For PocketsDesigned For Pockets– LaminatedLaminated

Provides Short Provides Short Statements On Correct Statements On Correct and Incorrect Practices and Incorrect Practices For A Specific JobFor A Specific Job– Wrong vs. RightWrong vs. Right

Contains Images Contains Images Showing Wrong and Showing Wrong and RightRight

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramTraining InstructionTraining Instruction

Sample Sample MS PowerPointMS PowerPoint Slides Slides

Adult LearningAdult Learning– For Training Trainers On For Training Trainers On

Presenting MaterialPresenting Material Ergonomics TrainerErgonomics Trainer

– Detailed Ergo Info and Areas of Detailed Ergo Info and Areas of Concern/SolutionsConcern/Solutions

Employee TrainingEmployee Training– Includes Basic Ergo Info Areas of Includes Basic Ergo Info Areas of

Concern/Solutions Concern/Solutions – What’s Wrong With This PictureWhat’s Wrong With This Picture

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramVideo - Working Video - Working

Smarter, Not HarderSmarter, Not Harder

Provides General Provides General Awareness On Ergonomics Awareness On Ergonomics – 15 Minutes Long15 Minutes Long

Presents Printing Presents Printing PerspectivePerspective– Common Risk Factors or Common Risk Factors or

StressorsStressors Includes Examples With Includes Examples With

Suggestions On How Suggestions On How Employees Can Do Their Employees Can Do Their Jobs SaferJobs Safer

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramTraining CD ROMTraining CD ROM

Containing:Containing:– Electronic Fact SheetsElectronic Fact Sheets– Extra ChecklistsExtra Checklists– Sample MS PowerPoint Sample MS PowerPoint

PresentationsPresentations– Training Evaluation Training Evaluation

FormForm– Employee Sign-in Employee Sign-in

SheetsSheets

Printing Ergonomics Printing Ergonomics Train-the-Trainer Train-the-Trainer

ProgramProgramNext StepsNext Steps

Materials Ready For Materials Ready For DistributionDistribution– Available for members and non-Available for members and non-

membersmembers Conduct TrainingConduct Training

– Train-the-Trainer Training at Train-the-Trainer Training at GATFGATF

– Regional Train-the-Trainer By PIA Regional Train-the-Trainer By PIA AffiliatesAffiliates

– Web conferences conducted by Web conferences conducted by SGIASGIA

Evaluation Evaluation

Printing Industry and Printing Industry and ErgonomicsErgonomics

Questions?Questions?